Polyethylene composition for pipe applications with improved sagging and extrusion properties

Abstract

The present invention relates to a polyethylene composition comprising, a base resin (A) comprising a copolymer of ethylene and at least one comonomer selected from alpha-olefins having from three to twelve carbon atoms, wherein the ethylene copolymer comprises a low molecular weight component (A-1) and a high molecular weight component (A-2) with the low molecular weight component (A-1) having a lower weight average molecular weight than the high molecular weight component (A-2), (B) carbon black in an amount of 1.0 to 10 wt % based on the total amount of the polyethylene composition, and (C) optional further additives other than carbon black; wherein the low molecular weight component (A-1) has a melt flow rate MFR2 (190° C., 2.16 kg) of equal to or more than 150 g / 10 min to equal to or less than 400 g / 10 min, determined according to ISO 1133, the base resin (A) has a density of equal to or more than 943 kg / m3 to equal to or less than 957 kg / m3, determined according to ISO 1183, and the composition has a melt flow rate MFR5 (190° C., 5 kg) of equal to or more than 0.14 g / 10 min to equal to or less than 0.30 g / 10 min, determined according to ISO 1133, a viscosity at a constant shear stress of 747 Pa, eta747, of equal to or more than 800 kPa*s to equal to or less than 1300 kPa*s, and complies with the in-equation (I) eta747>−1800×MFR5+1200 (I), a process for producing said polyethylene composition and an article comprising said polyethylene composition.

Description

[0001]This application is a 371 of PCT Patent Application Serial No. PCT / EP2016 / 000498, filed Mar. 22, 2016, which claims priority to European Patent Application Serial No. 15001844.8, filed Jun. 22, 2015.[0002]The present invention relates to a polyethylene composition, particularly a polyethylene composition for pipe applications. The invention further relates to a process for the production of said polyethylene composition and an article, particularly a pipe, comprising said polyethylene composition.BACKGROUND OF THE INVENTION[0003]Pipes constructed from polymer materials have a multitude of uses, such as fluid transport, i.e. the transport of liquids, slurries and gases, e.g. water or natural gas. During transport, it is normal for the fluid to be pressurized. Moreover, the transported fluid may have varying temperatures, usually within the range from about 0° C. to about 50° C. Such pressurized pipes are preferably constructed from polyolefin plastics, usually unimodal or bimod...

AI Technical Summary

Benefits of technology

[0022]The polyethylene composition according to the invention surprisingly not only show a low sagging tendency as can be seen from a high viscosity at a low shear stress of 747 Pa, but also good processability and extrudability which can be seen from the melt flow rate MFR5 and seen in the rheological properties such as a higher shear thinning index of the composition. Further the composition shows an improved balance of properties as regards mechanical properties, such as tensile properties, pressure resistance in the pressure pipe test. These properties enable the polyethylene composition of the present invention to be suitable for the production of thick-walled pipes, preferably with a wall thickness of 100 mm or more which preferably meet PE100 standards, with existing extrusion lines and standard adjustments of die heads.

[0102]In-equation (I) shows a correlation of the sagging tendencies and the flowability and processability of the polyethylene composition of the present invention. Since eta747 is related and proportional to the molecular weight of the composition, it is inversely proportional to the melt flow rate. Thus, a polyethylene composition complying with in-equation (I) surprisingly shows high eta747- and high MFR5-values indicating a high molecular weight and low sagging tendencies together with a high flowability and extrudability.

[0108]The polyethylene composition of the invention with the specific property balance between density, MFR and viscosity at low shear stress provide not only low sagging behavior but also highly advantageous mechanical properties e.g. for pipe applications, and processability properties, when the polyethylene composition is processed to articles, preferably pipes, as well as desirable resistance to internal pressure when tested using pipe samples of the polyethylene composition.

[0126]Usually, a multi-stage process is a process which makes use of at least two reactors, one for producing a lower molecular weight component (A-1) and a second for producing a higher molecular weight component (A-2). These reactors may be employed in parallel, in which case the components must be mixed after production. More commonly, the reactors are employed in series, such that the products of one reactor are used as the starting material in the next reactor, e.g. one component is formed in the first reactor and the second is formed in the second reactor in the presence of the first component. In this way, the two components are more intimately mixed, since one is formed in the presence of the other.

[0156]The polymerization process may further comprise a pre-polymerisation step which precedes the polymerisation steps. The purpose of the pre-polymerisation is to polymerise a small amount of polymer onto the catalyst at a low temperature and / or a low monomer concentration. By pre-polymerisation it is possible to improve the performance of the catalyst in slurry and / or modify the properties of the final polymer. The pre-polymerisation step may be conducted in slurry or gas phase. Preferably the pre-polymerisation is conducted in slurry.

[0181]The polymer melt is extruded through an annular die, which may be arranged either as end-fed or side-fed configuration. The side-fed dies are often mounted with their axis parallel to that of the extruder, requiring a right-angle turn in the connection to the extruder. The advantage of side-fed dies is that the mandrel can be extended through the die and this allows, for instance, easy access for cooling water piping to the mandrel.

Problems solved by technology

A problem when manufacturing large diameter pipes, particularly from multimodal polymer material, is that it is difficult to maintain uniform dimensions all over the pipe.

The sagging problem is particularly pronounced for thick-walled large diameter pipes, such as pipes with a wall thickness of at least 100 mm.

This leads to additional production costs due to the needed extra material and non optimal final product quality.

However, said polyethylene composition has a comparatively weak processability.